Circular stapling apparatus with pinned buttress

ABSTRACT

A stapling apparatus includes a staple cartridge, a pusher, and a buttress. The staple cartridge has a tissue contact surface and supports an array of fasteners therein. The pusher is configured to move relative to the staple cartridge to fire the fasteners from the staple cartridge. The buttress is supported on the staple cartridge and secured to the pusher.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 15/966,283, filed on Apr. 30, 2018, the entire contents of which are incorporated by reference herein.

TECHNICAL FIELD

The present disclosure relates to surgical stapling apparatus and, more particularly, to structures and methods for removably attaching buttress material to circular surgical stapling apparatus for use in anastomosis procedures.

BACKGROUND

Fasteners have traditionally been used to replace suturing when joining various body structures such as, for example, the bowel or bronchus. Surgical stapling apparatus employed to apply these fasteners are generally designed to simultaneously cut and seal tissue to reduce the time and risks involved with anastomosis procedures.

Circular surgical stapling apparatus are employed by surgeons to apply one or more surgical fasteners, e.g., staples or two-part fasteners, to body tissue for the purpose of joining segments of body tissue together and/or for the creation of anastomoses. Circular surgical stapling apparatus generally include an annular fastener cartridge assembly that supports a plurality of annular rows of fasteners, an annular anvil assembly operatively associated with the fastener cartridge assembly which provides a surface against which the fasteners are formed upon a firing of the circular stapling apparatus, and an annular blade for cutting tissue.

For most procedures, the use of bare fasteners, with the fasteners in direct contact with the patient's tissue, is generally acceptable. The integrity of the tissue will normally serve to prevent the fasteners from tearing out of the tissue and compromising the sealing before healing has occurred. However, in some surgical operations buttress materials are employed by surgeons in combination with circular stapling apparatus to bridge, repair and/or reinforce tissue defects within a patient. In particular, buttress materials reduce the trauma suffered by the patient, reduce the instances of leakage, reduce the instances of bleeding, and create a relatively strong bond between adjacent body tissues.

Accordingly, there is a need for reliably and removably attaching buttress material onto a circular stapling apparatus so that the buttress material does not interfere with the operation of the apparatus, remains on the apparatus until after the fasteners are fired, and is convenient and easy to install and use.

SUMMARY

According to one aspect, the present disclosure is directed to a stapling apparatus. The stapling apparatus includes a shell, a staple cartridge, a pusher, and a buttress. The staple cartridge is supported on the shell. The staple cartridge has a tissue contact surface and supports an array of fasteners therein. The pusher is positioned in the shell and is configured to move relative to the staple cartridge to fire the fasteners from the staple cartridge. The buttress is supported on the staple cartridge and includes legs that extend from the buttress. The legs are coupled to the pusher. The legs are configured to separate from the pusher as the pusher moves relative to the staple cartridge.

In some embodiments, the legs may extend along an outer surface of the shell. The shell may define windows in the outer surface thereof. The legs may be disposed in registration with the windows. The legs may include feet that are receivable through the windows and engageable with the pusher. The feet may be are pinned to the pusher. The feet may define pin openings therethrough and the pusher may define pin holes therein. The pin openings may be configured to align with the pin holes so that pins are receivable through the pin openings and the pin holes to secure the feet to the pusher. The pins may be configured to tear the feet as the pusher moves relative to the staple cartridge to enable the buttress to separate from the staple cartridge. The pusher may define recesses in registration with the pin holes. The feet may be disposed within the recesses.

In embodiments, the stapling apparatus may further include a knife movably supported in the shell to cut tissue supported on the staple cartridge.

In certain embodiments, the stapling apparatus may further include an anvil assembly that is selectively movable relative to the staple cartridge.

According to yet another aspect of the present disclosure, a circular stapling apparatus is provided. The circular stapling apparatus includes a staple cartridge, a pusher, and a buttress. The staple cartridge has a tissue contact surface and supports an array of fasteners therein. The pusher is configured to move relative to the staple cartridge to fire the fasteners from the staple cartridge. The buttress is supported on the staple cartridge and selectively pinned to the pusher.

In some embodiments, the buttress may include one or more legs that are pinned to the pusher.

The circular stapling apparatus may further include a shell that supports the staple cartridge and the pusher. The shell may define one or more windows in disposed in registration with the one or more legs of the buttress. The one or more legs may include a foot that is receivable through the one or more windows to engage the pusher. The foot may be pinned to the pusher by a hook. The foot may be configured to tear as the pusher moves relative to the staple cartridge.

In certain embodiments, the buttress includes three or more legs.

In embodiments, the circular stapling apparatus may further include a cylindrical knife positioned to move through the staple cartridge to cut tissue supported on the staple cartridge.

In some embodiments, the circular stapling apparatus may further include an anvil head that is selectively movable relative to the staple cartridge to clamp tissue between the anvil head and the staple cartridge.

Other aspects, features, and advantages will be apparent from the description, the drawings, and the claims that follow.

BRIEF DESCRIPTION OF DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and, together with a general description of the disclosure given above and the detailed description given below, serve to explain the principles of the disclosure, wherein:

FIG. 1 is a perspective view of a surgical stapling apparatus according to the present disclosure, the surgical stapling apparatus including one embodiment of an end effector shown in an unapproximated position;

FIG. 2 is an enlarged, perspective view of the indicated area of detail shown in FIG. 1;

FIG. 3 is a side, perspective view, with parts separated, of a buttress and a cartridge assembly of the end effector of FIG. 1;

FIG. 4 is a enlarged, perspective view of the buttress of FIG. 3;

FIG. 5 is an enlarged, perspective view of a pusher of the cartridge assembly of FIG. 3;

FIG. 6 is an enlarged, perspective view illustrating the buttress of FIG. 3 secured to the cartridge assembly of FIG. 3, the cartridge assembly shown with portions thereof in phantom for clarity;

FIG. 7 is a side, cross-sectional view of the end effector of FIG. 1 with the end effector illustrated in an approximated position;

FIGS. 8 and 9 are progressive views illustrating the end effector of FIG. 1 securing the buttress of FIG. 4 to tissue;

FIG. 10 is a perspective view of a portion of another embodiment of an end effector of the surgical stapling apparatus of FIG. 1; and

FIG. 11 is a perspective view illustrating of a portion of a buttress and a release pin of the end effector of FIG. 10.

DETAILED DESCRIPTION

Embodiments of the presently disclosed surgical stapling apparatus are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views. As commonly known, the term “clinician” refers to a doctor, a nurse, or any other care provider and may include support personnel. Additionally, the term “proximal” refers to the portion of structure that is closer to the clinician and the term “distal” refers to the portion of structure that is farther from the clinician. In addition, directional terms such as front, rear, upper, lower, top, bottom, and the like are used simply for convenience of description and are not intended to limit the disclosure attached hereto.

In the following description, well-known functions or constructions are not described in detail to avoid obscuring the present disclosure in unnecessary detail.

Turning now to FIGS. 1 and 2, a surgical stapling apparatus, generally referred to as 10. In embodiments, surgical stapling apparatus 10 is adapted for reuse and, in certain embodiments, the surgical stapling apparatus 10, or portions thereof, may be adapted for a single use and/or disposable. Surgical stapling apparatus 10 defines a centerline “CL” and includes a surgical device 100 in the form of a powered handheld electromechanical instrument. Surgical stapling apparatus 10 further includes an adapter assembly 200 that is selectively attachable to surgical device 100. Adapter assembly 200 extends distally from surgical device 100 and has an elongated body 202 that extends to a distal end. The distal end of elongated body 202 supports an end effector 300. End effector 300 includes a shell or cartridge assembly 310 and an anvil assembly 320 that are positionable between an unclamped or unapproximated position (see FIG. 1) and a clamped or approximated position (see FIG. 7) to selectively clamp tissue “T” (FIG. 9) for cutting and/or stapling tissue “T.” Surgical device 100 is configured for selective connection with adapter assembly 200, and, in turn, adapter assembly 200 is configured for selective connection with end effector 300. Together, surgical device 100 and adapter assembly 200 cooperate to operate end effector 300.

Surgical device 100 of surgical stapling apparatus 10 includes a handle housing 102 configured for selective removable receipt of a rechargeable battery 103. Battery 103 is configured to supply power to electrical components of surgical device 100. Handle housing 102 defines a cavity “C” that supports a controller or circuit board 105 therein that is configured to control various operations of surgical device 100.

Surgical stapling apparatus 10 further includes a drive mechanism 106 configured to drive rotatable shafts and/or gear components (not shown) within handle housing 102 in order to perform various operations of surgical stapling apparatus 10. For instance, drive mechanism 106 may be operable to selectively rotate end effector 300 about, and/or relative to, the centerline “CL” of surgical stapling apparatus 10; to selectively move anvil assembly 320 relative to the cartridge assembly 310 to selectively clamp tissue; and/or to fire surgical stapling apparatus 10 for fastening and/or cutting the clamped tissue. Battery 103, controller 105, and/or drive mechanism 106 may be operably coupled to one or more actuators 107 a, 107 b such as finger-actuated control buttons, rocker devices, and/or the like to effectuate various functions of surgical stapling apparatus 10 such as those described above.

Drive mechanism 106 of electromechanical surgical stapling apparatus 10 includes an approximation mechanism 108 that extends distally through elongated body 202. Approximation mechanism 108 is configured to selectively or removably couple to anvil assembly 320 as described in U.S. Pat. No. 7,303,106 to Milliman et al., the entire contents of which are incorporated by reference herein. Approximation mechanism 108 is also configured to move along centerline “CL” of surgical stapling apparatus 10, between distal and proximal positions, to move anvil assembly 320 between approximated and unapproximated positions relative to cartridge assembly 310 to selectively clamp and/or unclamp tissue.

Reference may be made to U.S. Pat. No. 8,806,973 to Ross et al., the entire contents of which are incorporated herein by reference, for a detailed description of the construction and operation of an example electromechanical surgical stapling apparatus, the components of which are combinable and/or interchangeable with one or more components of surgical stapling apparatus 10 described herein.

Although surgical stapling apparatus 10 is described as an electromechanically powered surgical stapling apparatus, the presently disclosed surgical stapling apparatus can be provided as a manually powered stapling apparatus. For a more detailed description of the construction and operation of an exemplary manually powered stapling apparatus, one or more components of which can be combined and/or interchanged with the electromechanically powered stapling apparatus described herein, reference can be made to U.S. Pat. No. 5,915,616 to Viola et al., U.S. Pat. No. 8,109,426 to Milliman et al., U.S. Pat. No. 8,272,552 to Holsten et al., U.S. Pat. No. 9,504,470 to Milliman, and U.S. Pat. No. 9,414,839 to Penna, the entire contents of which are incorporated by reference herein.

Turning now to FIGS. 2-7, anvil assembly 320 of end effector 300 includes an anvil head 322 and a center rod assembly 324 that extends proximally from anvil head 322. For a more detailed description of anvil assembly 320, reference can be made to U.S. Pat. No. 7,303,106 to Milliman et al., which is incorporated by reference herein above.

Cartridge assembly 310 of end effector 300 includes a shell 312, a pusher 313 for firing fasteners “F” into anvil assembly 320, a cylindrical knife 314 for cutting tissue, a staple cartridge 315 for supporting fasteners “F” in cartridge assembly 310, a buttress 316, and pins 318 that secure buttress 316 to shell 312. Pins 318 include a pin head 318 a and a pin shaft 318 b that extends distally from pin head 318 a. Cartridge assembly 310 further includes an outer drive sleeve 317 configured to distally advance pusher 313 relative to staple cartridge 315, as indicated by arrows “A,” and an inner drive sleeve 319 supported on outer drive sleeve 317. Inner drive sleeve 319 is configured to distally advance cylindrical knife 314 relative to staple cartridge 315, as indicated by arrows “B,” when outer drive sleeve 317 distally advances pusher 313 relative to staple cartridge 315 for forming fasteners “F” (e.g., staples) against anvil head 322 of anvil assembly 320.

Shell 312 of cartridge assembly 310 is secured to a distal end portion of elongated body 202 of adapter assembly 202 (FIG. 1). Shell 312 includes an outer housing 312 a configured to support staple cartridge 315, and an inner housing 312 b configured to receive center rod assembly 324 of anvil assembly 320 therein, and a coupling portion 312 x configured to couple cartridge assembly 310 to elongated body 202 of adapter assembly 200. Outer housing 312 a defines windows 312 c at circumferentially spaced locations about outer housing 312 a.

Pusher 313 of cartridge assembly 310 is slidably positioned about inner housing 312 b of shell 312 and defines a central throughbore 313 a. Pusher 313 includes annular arrays of distally extending fingers 313 b configured to support an array of fasteners “F.” One or more of fingers 313 b and/or one or more of fasteners “F” may have different heights. In some embodiments, one or more of fingers 313 b and/or one or more of fasteners “F” may have the same height. Pusher 313 defines an array of pin holes 313 c positioned at circumferentially spaced positions about pusher 313 and supported on lower portion thereof. Pin holes 313 c are disposed in fluid communication with throughbore 313 a and are positioned within recesses 313 d formed in an outer surface of pusher 313. Each recess 313 d may taper or curve radially inward toward a respective one of pin holes 313 c to facilitate insertion of pins 318 within pin holes 313 c. Recesses 313 d may have a frustoconical configuration.

Cylindrical knife 314 of cartridge assembly 310 is frictionally retained within central throughbore 313 a of pusher 313 to fixedly secure knife 314 in relation to pusher 313. The distal end of knife 314 includes a circular cutting edge 314 a configured to severe tissue.

Staple cartridge 315 of cartridge assembly 310 includes a tissue contact surface 315 a in which annular arrays of slots 315 b are formed. Annular arrays of slots 315 b of the staple cartridge 315 are configured to support and slidably receive annular arrays of fasteners “F” therein.

Buttress 316 of cartridge assembly 310 includes an annular ring 316 a that is configured to mount to tissue contact surface 315 a of staple cartridge 315 and legs 315 b that extend proximally from annular ring 316. Legs 315 b are positioned at circumferentially spaced apart locations relative to one another about annular ring 316 and extend along an outer surface of outer housing 312 a of shell 312. Legs 315 b are positioned in registration with windows 312 c of shell 312 when annular ring 316 a is mounted to tissue contact surface 315 a of staple cartridge 315. Each leg 316 b includes a foot 316 c that defines a pin opening 316 d therethrough. Each foot 316 c is radially offset from its leg 316 b (inwardly) and is configured to be received within a respective window 312 c of shell 312 so that pin openings 316 d of feet 316 c align with respective pin holes 313 c of pusher 313. Pins 318 secure feet 316 c to pusher 313 when pin shafts 318 b of pins 318 are frictionally secured within pin holes 313 c of pusher 313. In particular, pin heads 318 a of pins 318 trap feet 316 c of legs 316 b of buttress 316 against the outer surface of pusher 313 within respective recesses 313 d of pusher 313. Each foot 316 c includes a heel 316 e that connects the respective foot 316 c to its leg 316 b and extends radially inward from its leg 316 b to couple to a base 316 f of the respective foot 316 c. Base 316 f of foot 316 c extends distally from heel 316 e of foot 316 c and in parallel relation to its leg 316 b. Base 316 f defines pin hole 313 c therethrough. Foot 316 c further includes a toe 316 g that extends distally from base 316 f of foot 316 c and is positioned at an angle relative to base 316 f.

Referring now to FIGS. 7-9, in operation, once end effector 300 of the surgical stapling apparatus 10 is positioned adjacent to a surgical site, anvil assembly 320 of end effector 300 can be approximated toward cartridge assembly 310 of end effector 300 to grasp tissue between cartridge and anvil assemblies 310, 320. Stapling apparatus 10 can then be fired so that outer and inner drive sleeves 317, 319 distally advance pusher 313 and cylindrical knife 314 for firing fasteners “F” into tissue “T” and cutting the tissue “T.” As pusher 313 is advanced through staple cartridge 315 for firing fasteners “F” therefrom, pins 318 tear through feet 316 c of buttress 316 so that buttress 316 separates from cartridge assembly 310—advantageously without applying staple line pressure—as fired fasteners “F” secure buttress 316 to tissue “T.” Anvil assembly 320 of end effector 300 can then be unapproximated or separated from cartridge assembly 310 of end effector 300 to release the stapled tissue and remove end effector 300 from the surgical site. Anvil and/or cartridge assemblies 310, 320 can be removed from the surgical stapling apparatus 10 and/or replaced. For a more detailed description of firing, cutting, and/or fastening of fasteners “F” and/or replacement of anvil and/or cartridge assemblies 310, 320, reference can be made to U.S. Pat. No. 7,303,106, incorporated herein by reference above.

With reference to FIGS. 10 and 11, another embodiment of a buttress 416 and another embodiment of a pin 418 are illustrated. Buttress 416 is substantially similar to buttress 316 but a foot 416 a thereof does not include a toe. Pin 418 includes a hook 418 a and a shaft 418 b that extends distally from hook 418 a. Pin 418 further defines a recess 418 c disposed between hook 418 a and shaft 418 b that is configured to retain foot 416 a therein.

As can be appreciated, securement of any of the components of the presently disclosed apparatus can be effectuated using known securement techniques such welding, crimping, gluing, fastening, etc.

The various embodiments disclosed herein may also be configured to work with robotic surgical systems and what is commonly referred to as “Telesurgery.” Such systems employ various robotic elements to assist the clinician and allow remote operation (or partial remote operation) of surgical instrumentation. Various robotic arms, gears, cams, pulleys, electric and mechanical motors, etc. may be employed for this purpose and may be designed with a robotic surgical system to assist the clinician during the course of an operation or treatment. Such robotic systems may include remotely steerable systems, automatically flexible surgical systems, remotely flexible surgical systems, remotely articulating surgical systems, wireless surgical systems, modular or selectively configurable remotely operated surgical systems, etc.

The robotic surgical systems may be employed with one or more consoles that are next to the operating theater or located in a remote location. In this instance, one team of clinicians may prep the patient for surgery and configure the robotic surgical system with one or more of the instruments disclosed herein while another clinician (or group of clinicians) remotely controls the instruments via the robotic surgical system. As can be appreciated, a highly skilled clinician may perform multiple operations in multiple locations without leaving his/her remote console which can be both economically advantageous and a benefit to the patient or a series of patients. For a detailed description of exemplary medical work stations and/or components thereof, reference may be made to U.S. Patent Application Publication No. 2012/0116416, and PCT Application Publication No. WO2016/025132, the entire contents of each of which are incorporated by reference herein.

Persons skilled in the art will understand that the structures and methods specifically described herein and illustrated in the accompanying figures are non-limiting exemplary embodiments, and that the description, disclosure, and figures should be construed merely as exemplary of particular embodiments. It is to be understood, therefore, that the present disclosure is not limited to the precise embodiments described, and that various other changes and modifications may be effected by one skilled in the art without departing from the scope or spirit of the disclosure. Additionally, it is envisioned that the elements and features illustrated or described in connection with one exemplary embodiment may be combined with the elements and features of another without departing from the scope of the present disclosure, and that such modifications and variations are also intended to be included within the scope of the present disclosure. Indeed, any combination of any of the presently disclosed elements and features is within the scope of the present disclosure. Accordingly, the subject matter of the present disclosure is not to be limited by what has been particularly shown and described. 

What is claimed is:
 1. A stapling apparatus, comprising: a shell; a staple cartridge supported on the shell, the staple cartridge having a tissue contact surface and supporting an array of fasteners therein; a pusher positioned in the shell and configured to move relative to the shell to fire the fasteners from the staple cartridge; and a buttress supported on the staple cartridge and coupled to the pusher.
 2. The stapling apparatus of claim 1, wherein the buttress includes legs that connect to the pusher.
 3. The stapling apparatus of claim 2, wherein the shell defines windows in the outer surface thereof, the legs extending along the outer surface of the shell and are disposed in registration with the windows.
 4. The stapling apparatus of claim 3, wherein the legs include feet, wherein the feet are receivable through the windows and engageable with the pusher.
 5. The stapling apparatus of claim 4, wherein the feet are pinned to the pusher.
 6. The stapling apparatus of claim 5, wherein the feet define pin openings therethrough and the pusher defines pin holes therein, the pin openings configured to align with the pin holes so that pins are receivable through the pin openings and the pin holes to secure the feet to the pusher.
 7. The stapling apparatus of claim 6, wherein the pins are configured to tear the feet as the pusher moves relative to the staple cartridge to enable the buttress to separate from the staple cartridge.
 8. The stapling apparatus of claim 6, wherein the pusher defines recesses in registration with the pin holes, the feet disposed within the recesses.
 9. The stapling apparatus of claim 1, further comprising a knife movably supported in the shell to cut tissue supported on the staple cartridge.
 10. The stapling apparatus of claim 1, further comprising an anvil assembly that is selectively movable relative to the staple cartridge.
 11. A stapling apparatus, comprising: a staple cartridge having a tissue contact surface and supporting an array of fasteners therein; a pusher configured to move relative to the staple cartridge to fire the fasteners from the staple cartridge; and a buttress supported on the staple cartridge and secured to the pusher.
 12. The stapling apparatus of claim 11, wherein the buttress includes at least one leg that is pinned to the pusher.
 13. The stapling apparatus of claim 12, further comprising a shell that supports the staple cartridge and the pusher.
 14. The stapling apparatus of claim 13, wherein the shell defines at least one window in disposed in registration with the at least one leg of the buttress.
 15. The stapling apparatus of claim 14, wherein the at least one leg includes a foot, wherein the foot is receivable through the at least one window to engage the pusher.
 16. The stapling apparatus of claim 15, wherein the foot is pinned to the pusher by a hook.
 17. The stapling apparatus of claim 16, wherein the foot is configured to tear as the pusher moves relative to the staple cartridge.
 18. The stapling apparatus of claim 11, wherein the buttress includes at least three legs.
 19. The stapling apparatus of claim 11, further comprising a cylindrical knife positioned to move through the staple cartridge to cut tissue supported on the staple cartridge.
 20. The stapling apparatus of claim 11, further comprising an anvil head that is selectively movable relative to the staple cartridge to clamp tissue between the anvil head and the staple cartridge. 